Conversion of polymer containing materials to petroleum products

ABSTRACT

Systems and methods achieve the conversion of polymer containing material into petroleum products such as hydrocarbon gas, wax, crude oil and diesel. The reactor and its system are designed to subject the polymer containing material to pyrolysis in a way that results in a higher petroleum product yield than conventional existing systems. The system has controls which allow for the heating temperature, rotation of the body, and throughput rate, to be adjusted depending on the reaction time required for the material inside the reactor. The condensing system is able to separate the products into the desired petroleum products by percentage output ranging from wax to crude-like oil to diesel-quality oil.

Embodiments of the invention relate to systems and methods forconverting polymer containing materials to petroleum products such ashydrocarbon gases, wax, crude oil and diesel.

BACKGROUND

Conventional technology is directed to converting polymer containingmaterials such as plastic into petroleum products including crude oil.Unfortunately, conventional technology is limited to relatively lowcrude oil and diesel yields, slower throughput, higher operating costs,and higher capital expenses.

SUMMARY

Embodiments of the invention address several limitations of othertechnologies. In some embodiments, the reactor, the system and themethod used lead to a higher yield of crude oil and diesel, with aquicker throughput rate, on a lower operating expense, and at a lowercapital expense. Specifically, the focus is on producing as muchdiesel-quality oil as possible and minimize the wax that othertechnologies create by ensuring an ideal reaction time, and allowinglower carbon chains more time to develop into diesel. Further,embodiments of the reactor allow for a shorter reaction time thatresults in more polymer containing materials converting into vapors thatlead to petroleum products each minute and hence each hour and day. Inaddition, embodiments of the reactor are designed such that the processcan be run continuously 24 hours per day, 7 days per week, thusincreasing or maximising output. In some embodiments, the overall systemis intended to be as automated as possible so that minimal interventionis required, thus requiring a small workforce of 1-3 employees. Finally,the design of the system, in particular the reactor, does not requiresignificant capital expenditure to build. This means that the system canhave a shorter payback period than others available for sale.

In some embodiments, the invention includes a system and method forproducing petroleum products such as wax, gas and oil by the pyrolysisof polymer containing materials and the subsequent condensation of theresultant vapors. The polymer containing material is initiallypre-processed as necessary depending on the composition of the polymercontaining material (if known). Once the polymer containing materialenters the system it is pre-melted and moved into the reactor body whereit is subjected to a similar or higher temperature. The reactor includesa generally horizontal cylindrical body that has an inlet at the firstend, at least one outlet at the other end and which is sealed (fromoutside atmosphere) on both ends, with an inclined slope of the body offof horizontal, external heating applied along one or more sides of thebody, and one or more internal rotating augers. The body of the reactoris designed with the ability to rotate the body. Also, the ability tovary the revolutions per minute of the rotating body is possible anddependent on the reaction needs.

The condensers used in the invention include several in a process, aswell as additional condensing systems. The pressure and temperatureswithin each condenser can be adjusted so that different percentages ofpetroleum products are produced. In some embodiments the system includesmore than one reactor to be used either in sequence or in parallel. Theadditional reactors can be used for both additional polymer containingmaterials as well as for that which remains unreacted after goingthrough a reactor. This allows for higher throughput rate, as well ashigher yield.

In some embodiments the invention includes the use of a controlmechanism which allows different parameters of the system to be capturedand monitored. If certain parameters are found to be outside the desiredrange, they can be adjusted either manually by users or automaticallythrough the control mechanism. In some embodiments the system and methodincludes processing the feedstock of polymer containing materials priorto them entering the reactor and reaction stage. This is done to removeunwanted particles such as dust and fibers, as well as to separate outundesired polymer containing materials.

Other aspects and advantages of embodiments of the present inventionwill become apparent from the following detailed description, taken inconjunction with the accompanying drawings, illustrated by way ofexample of the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments of the present invention are shown and described inreference to the numbered drawings wherein:

FIG. 1 is a flow diagram of one embodiment of the system of the presentinvention.

FIG. 2 is a view of one embodiment of the feeder.

FIG. 3 is an alternative view of one embodiment of the feeder.

FIG. 4 is a view of the feedstock being fed into the reactor body.

FIG. 5 is an alternative view of the feedstock being fed into thereactor body.

FIG. 6 is a view of one embodiment of the feeder.

FIG. 7 is a view of the vertical section of the condenser.

FIG. 8 is a flow diagram of the embodiment of the invention with asecond reactor body.

FIG. 9 is a flow diagram showing an embodiment of the invention with thevapor gas product used to heat the reactor.

FIG. 10 is a view of the back end of the reactor body with oneadditional auger to remove the residue.

FIG. 11 is an alternative view of the back end of the reactor body witha different auger to remove the residue.

FIG. 12 is a view of the front end of the reactor body and an embodimentof how the internal auger can rotate.

FIG. 13 is a view of the front end of the reactor body and an embodimentof how the internal auger can counter-rotate.

FIG. 14 is a view of the front end of the reactor body and an embodimentof how the internal auger can rotate around the body.

FIG. 15 is a view of the front end of the reactor body and an embodimentof how the internal auger can rotate with the use of a scraper.

FIG. 16 is a view of the front end of the reactor body and an embodimentof how two internal counter rotating augers can work.

FIG. 17 is an alternate view of the front end of the reactor body and anembodiment of how two internal counter-rotating augers can work.

FIG. 18 is a view of the front end of the reactor body and an embodimentof how two internal co-rotating augers can work.

FIG. 19 is a flow diagram showing an embodiment of the invention withtwo reactor bodies using two condenser systems.

FIG. 20 is a view of the longitudinal side of the reactor body with anembodiment of the mechanism which alters the slope angle.

FIG. 21 is a flow diagram showing an embodiment of the invention with acontrol system that monitors several parameters and has the ability tomodify those parameters.

FIG. 22 is a side view of a pre-reactor process that includes severalapparatus designed to prepare the polymer containing materials forconversion in the reactor.

It is intended that the drawings are illustrative of the broader scopeand embodiments of the invention, and the embodiments of the inventionare not limited to these figures.

Throughout the description, similar reference numbers may be used toidentify similar elements.

DETAILED DESCRIPTION

It will be readily understood that the components of the embodiments asgenerally described herein and illustrated in the appended figures couldbe arranged and designed in a wide variety of different configurations.Thus, the following more detailed description of various embodiments, asrepresented in the figures, is not intended to limit the scope of thepresent disclosure, but is merely representative of various embodiments.While the various aspects of the embodiments are presented in drawings,the drawings are not necessarily drawn to scale unless specificallyindicated.

The present invention may be embodied in other specific forms withoutdeparting from its spirit or essential characteristics. The describedembodiments are to be considered in all respects only as illustrativeand not restrictive. The scope of the invention is, therefore, indicatedby the appended claims rather than by this detailed description. Allchanges which come within the meaning and range of equivalency of theclaims are to be embraced within their scope.

Reference throughout this specification to features, advantages, orsimilar language does not imply that all of the features and advantagesthat may be realized with the present invention should be or are in anysingle embodiment of the invention. Rather, language referring to thefeatures and advantages is understood to mean that a specific feature,advantage, or characteristic described in connection with an embodimentis included in at least one embodiment of the present invention. Thus,discussions of the features and advantages, and similar language,throughout this specification may, but do not necessarily, refer to thesame embodiment.

Furthermore, the described features, advantages, and characteristics ofthe invention may be combined in any suitable manner in one or moreembodiments. One skilled in the relevant art will recognize, in light ofthe description herein, that the invention can be practiced without oneor more of the specific features or advantages of a particularembodiment. In other instances, additional features and advantages maybe recognized in certain embodiments that may not be present in allembodiments of the invention.

Reference throughout this specification to “one embodiment,” “anembodiment,” or similar language means that a particular feature,structure, or characteristic described in connection with the indicatedembodiment is included in at least one embodiment of the presentinvention. Thus, the phrases “in one embodiment,” “in an embodiment,”and similar language throughout this specification may, but do notnecessarily, all refer to the same embodiment.

While many embodiments are described herein, an embodiment of anapparatus converts polymer containing materials into petroleum products(mostly oil) at various boiling ranges. FIG. 1 shows that the apparatusincludes a feeder part 12, a reactor part 14, and a condenser systempart 18. Polymer containing material is fed through an inlet 10 in thefeeder, and heat is applied to the reactor 16, while there is an outletfrom the condenser for the product to exit from 20.

The polymer containing material fed into the feeder can include chips,shredded, ground, or any other type of shape containing at least aportion of polymer material. The size of polymer containing material isonly constrained by the size of the feeder. Using a smaller size(one-half inch minus) makes the bulk material denser and makes it easierto move the bulk material at a consistent mass flow. The polymercontaining material may be fed from the feeder into the reactor aseither a dry feed or a hot melt feed. FIG. 2 shows that the polymercontaining material feed is fed through an inlet 22 into the feeder 24from which ambient polymer containing material at a temperature range of30-125° F. exits 26.

FIG. 3 shows that the same polymer containing material feed 32 can beput through the feeder 34 and heated to produce hot melted polymercontaining material 36 which exits at a temperature range of 250-600° F.At this elevated temperature the material is melted to a point where itis closer to a liquid consistency. Having the material enter the reactorat an elevated temperature helps keep the reactor temperature steady asintroducing colder material drops the overall temperature of material inthe reactor. The feeder can be used to increase the density of thematerial as well as to pre-heat the material before it is brought to thereactor.

FIG. 4 shows that the polymer containing material 42 can be metered fromthe feeder 46 into the reactor 48 with an auger or screw 44. Therevolutions per minute of the auger or screw determine the mass flowrate of the material. The auger can be cooled with a cooling jacket toprevent the polymer containing material from pre-melting as it travelsthrough the screw. In one embodiment, the feed mechanism extends fromthe feeder into the reactor body.

FIG. 5 shows the mechanical force 54 which results in viscous heating,in addition to external heating 56, serve to melt the polymer containingmaterial 52 while pushing the material forward. The RPM of the auger orscrew determines the mass flow of the material. Once the material issufficiently melted it can be pushed through a channel 60 into thereactor 62.

FIG. 6 shows an alternative feeder 64, in this case a melt vessel, inwhich the feed of melted wax, hot oil, melted material, or a combinationthereof is fed. The material 68 is heated and mixed in the melt vesseland is then metered into the reactor 70 either by gravity or a hot pump66.

FIG. 7 shows an example of a four stage condensing system whichcondenses vapors at four different temperatures. The main purpose of thecondensing system is to cool the hot vapors enough for condensation tooccur and for them to be in a liquid phase. The condensing system canalso be configured to do this cooling in stages in order to separatedifferent boiling ranges of the product. The result of a four stagecondensing system is the separation of four distinct liquid products.Hot vapor 71 that is produced in the reactor is drawn through thecondensing system starting with the first condenser 72. The vapor leavesthe first condenser as either a liquid 74 at a temperature between 200°F. and a maximum of what the temperature of the reactor is or as a vapor73. The vapor that exits the first condenser moves into the secondcondenser 76 where it is set at a lower temperature than the firstcondense but at least higher than 50° F. Again the vapor leaves thesecond condenser either in liquid form 75 or as vapor 77 that proceedsinto the third condenser 78. In this third condenser the vapor is againcooler further at a temperature lower than that of the second condenserbut at least higher than 50° F. From this third condenser the vaporleaves as either liquid 79 or as vapor 80 into the fourth condenser 82.In this fourth condenser the vapor is cooled down significantly betweenabout room temperature to at least above −30° F. to capture the last ofthe available liquids 83 with the remainder exiting as vapor 81 whichwill typically be light hydrocarbon gases comprised of non-condensablegases usually with a carbon number less than 5. Although specifictemperatures and/or temperature ranges are mentioned in this example,other embodiments may operate at other temperatures or temperaturecombinations.

FIG. 8 shows another design in which reacted product from the firstreactor 85 is fed back into a second reactor 90. After the material 84is fed in through the reactor 85 and exits as vapor it enters the firstcondenser 86. From this first condenser the vapor can either move intothe second condenser 87, or exit as product 91, in which case theproduct 91 can be redirected into the additional reactor 90 where itwill be further subjected to further heating. This further reaction isdone primarily to further crack heavy wax products with a high boilingpoint. From the second reactor, the liquid can either be redirected asoil feedback 88 back into the first reactor 85 for further heating orexit as liquid 91. The vapor from the second condenser will enter thethird condenser 89 where again it will exit as either liquid product 93or as a vapor gas product 94. In this example the vapor gas product 94is not further cracked in a fourth condenser.

FIG. 9 shows an alternate design to FIG. 8 in which the vapor gasproduct 94 from the condenser 87 is redirected to use as the energysource of the combustion heat source 95 that heats the first reactor 85.

FIG. 10 shows the rear view of one embodiment of the reactor body 100.Inside the body lays the main reactor chamber 102 in which there liesinternal reactor augers 104 and 106. In this example the first auger 104rotates counter-clockwise and the second auger 106 rotates clockwise andhence they are counter-rotating augers. In some embodiments, the reactoraugers help scrape the char and residue off the reactor wall and helpcarry it to the read end of the reactor body. In the illustratedembodiment, a third excavating auger 108 is placed perpendicular to thereactor body to capture the unreacted residue as it exits the reactor.The third auger moves the residue to its exit point 110 where it can becaptured and stored.

FIG. 11 shows an alternate setup to the one used in FIG. 10. Theinternal reactor augers 114 and 116 are co-rotating (i.e., in the samerotational direction) inside the reactor body 112. The third excavatingauger 118 is placed in line with the reactor body, directly underneathand behind the reactor body. The auger serves the same purpose as thatof auger 108 in FIG. 10.

FIG. 12 shows the inside of the reactor body. In this embodiment, thereactor body 120 is rotating clockwise 122 and the internal rotatingauger 126 is also rotating clockwise.

FIG. 13 shows an alternative embodiment of the invention. The reactorbody 130 is rotating clockwise 132 whereas the internal rotating auger134 is rotating counter-clockwise.

FIG. 14 shows a third alternative embodiment of the invention. In thiscase, the reactor body 140 is rotating counter-clockwise 142 and theinternal rotating auger 144 is also rotating counter-clockwise 146.

FIG. 15 shows a fourth embodiment of the invention. In this case, thereactor body 150 is rotating counter-clockwise 152. In addition to arotating auger 154, there is also a scraper 156 that removes solids thathave fallen.

FIG. 16 shows a fifth embodiment of the invention. In this case, thereactor body 160 is rotating clockwise 162. There are two internalcounter-rotating augers 164. One is rotating counter-clockwise 166 andone clockwise 168.

FIG. 17 shows a sixth embodiment of the invention. In this case, thereactor body 170 is rotating clockwise 172. There are two internalcounter-rotating augers 174. The first is rotating counter-clockwise 176and the second clockwise 178.

FIG. 18 shows a seventh embodiment of the invention. In this case, thereactor body 180 is rotating clockwise 182. There are two co-rotatingaugers 184. The first is rotating clockwise 186 and the second is alsorotating clockwise 188.

FIG. 19 shows an embodiment of the invention in which two reactors andtwo condensers are used. The feed in 190 is fed into the first reactor192 out of which both gas vapor 194 and char/residue 196 exit. The gasvapor enters the first condenser 198 from which two products 200 and 202exit. The second product 202 as well as the char/residue from the firstreactor enter the second reactor 204. Gas vapor 206 exits the secondreactor and enters a second condenser 208. A third product 210 iscreated from the second condenser.

FIG. 20 illustrates how the feedstock 211 enters the reactor body 212and the one or more augers or scrapers 213 push the feedstock forward.The reactor body is kept at an incline 214 which is off horizontal andbetween 0 and 30 degrees. This incline helps with the reaction, allowingfor adjustments to achieve an optimal residence time that increases theyield.

The reactor is rotated at a RPM as per the operating conditions anddesired fuel output. The ideal RPM of the rotation of the reactor isguided by the RPM of the internal augers which mix the polymercontaining materials inside the reactor. The rotating action of thereactor facilitates stirring and mixing of the feed materials on theinside and also allows for even heating of the exterior wall of thereactor chamber. The reactor heats and stirs the polymer containingmaterial or wax to a state of being a liquid material. In oneembodiment, the liquid in the reactor temperature is 400-550° C. Inother embodiments, the liquid may be a higher or lower temperature. Thereactor includes a longitudinally situated cylindrical tube which isindirectly heated on the exterior. This could be heated with hot gasesfrom a combustion source or hot gases from an electric source.

In other embodiments, there can be a heating source which heats thelength of the outer wall of the reactor. The temperature of the outerwall of the reactor as well as of the inner wall of the reactor may bemonitored and controlled to ensure proper and stable reactionconditions. If the temperature is not steady it can be adjusted throughthe heating source to ensure a stable reaction. This helps to avoid bothunder-heating and over-heating the reaction which can lead to loweryields.

Inside the reactor chamber, there may be one or more augers which serveto stir the liquid reactant as well as scrap material from the reactortube's interior walls. The augers are rotated such that the linear speedat which they carry material forward is controlled—the material that ismoved is the dry char which is to be carried out of the reactor. Theaugers must be fast enough to accommodate the excavation of the char sothat the char does not backup inside the reactor. The auger(s) pitch anddiameter are designed to operate within the necessary speed range tocarry any solid char material out of the reactor at a rate that is equalto or greater than the rate at which char is produced.

In the reactor the liquid material is reacted through pyrolysis whichbreaks the long molecules into shorter molecules. When a molecule issufficiently cracked and is heated to the chosen reaction temperature,typically between 400-550° C., this molecule will be changed to a vaporor gas phase. However, the exact temperature or range may depend on thetype of reactants that are cracked and/or the combinations of productsthat are mixed with the reactants.

Changing the degree of the incline of the reactor so that it slopesbetween 0-30% grade allows for the throughput rate to be increased ordecreased depending on the need. A plug or a baffle may be used near theback of the reactor body to reduce the heat loss and ensure the vapordoes not condense at the exit where the char is being removed.

In some cases more crude oil will be desired, and at other times diesel.Once the gases are of the desired carbon length range, they arecondensed in the condenser system to yield oil at the preferred boilingtemperatures. The vapor that exists in the reactor will be drawn intothe condenser system via a slight vacuum pressure differential. Thevacuum in the reactor is in the range of −0.25″ to −1.5″ WC, whereas thevacuum in the condenser is in the range of −0.5″ to 2.0″ WC.

The condenser is used to cool the hot vapors that are produced from thereactor. When these vapors are cooled, a large portion of them willchange from a vapor phase to a liquid phase. This cooling can be done instages which will separate the vapors into different liquid productstreams based on boiling point temperatures. The products are removedfrom the condenser at approximately the same rate they are produced.

In the condenser system the vapor hydrocarbon gases are systematicallycondensed by decreasing the temperature and thus condensing into chosenboiling ranges. The yield of oil from the feedstock can be impacted bythe type of polymer containing material which is fed into the system, asdifferent materials have different molecular structures which impact thepotential oil yield.

A refrigerated condenser can condense more vapor—for example if onecondenser is set at approximately normal room temperature it can get thelight oil out of the product stream. The different products can beblended or used separately for specific end purposes such as dieselfuel, gasoline, crude oil, fuel oil, etc.

The inventors have used different catalysts with the invention and havefound that some decrease the reaction time as well as increase the yieldof oil. The use of particular catalysts improve the invention and can beadded to the feedstock uniformly as it enters the reactor body.

FIG. 21 illustrates one embodiment of a control system that allows usersof the invention to both monitor the overall reaction process, as wellas automate or manually alter operating conditions. The inputs 216 whichare different parameters that are monitored can include but is notlimited to the feed rate and temperature of the polymer containingmaterial, the RPM of the reactor, the temperature and pressure insidethe reactor, the temperature and pressure inside the condensers, the oillevel inside the condenser, the oil production rate, the yield of oil,the breakup of which types of oils are produced and in what percentage,the non-condensable gas flow rate, the gas yield, the char productionrate, the char production yield, etc. The process monitor display 218allows users to track each of the parameters. 218 can also include acontroller which can either automatically adjust the parameters toensure it remains within a targeted range (e.g. if the oil yield is low,the feed rate of the polymer containing materials can be slowed down),or can be manually altered by users (e.g. if more crude oil is desired,the user can manually alter the temperature and pressure inside one ormore of the condensers). The outputs 220 are the reaction controls andinclude the feed rate of the polymer containing material, the heatingsource of the reactor, the mechanism which rotates the reactor, thepressure inside the reactor, the pressure inside the condensers, the oildrain rate of the condensers, etc.

FIG. 22 is an example of how the polymer containing material can beprepared pre-reaction. Polymer containing materials enter at 221 wherethey are typically polluted with unwanted fibers and dust. They areplaced into the first apparatus 222 in which the material is dropped.The lighter undesired particles such as dust tend to float above 224while the actual polymer containing materials drop to the bottom 223where they are captured and pushed into the second apparatus 225. In thesecond apparatus 225 a fluid with a known density is chosen so that thepolymer containing materials are separated by their densities. Thosewith a lower density will float at the top and those with a higherdensity will sink to the bottom 226. What floats can be then directed227 into the third apparatus 228 in which the polymer containingmaterials are dried. Once the fluid has been separated out 229 in thisdrying process, the dry polymer containing materials 230 are ready forreaction.

In the above description, specific details of various embodiments areprovided. However, some embodiments may be practiced with less than allof these specific details. In other instances, certain methods,procedures, components, structures, and/or functions are described in nomore detail than to enable the various embodiments of the invention, forthe sake of brevity and clarity.

Although the operations of the method(s) herein are shown and describedin a particular order, the order of the operations of each method may bealtered so that certain operations may be performed in an inverse orderor so that certain operations may be performed, at least in part,concurrently with other operations. In another embodiment, instructionsor sub-operations of distinct operations may be implemented in anintermittent and/or alternating manner.

Although specific embodiments of the invention have been described andillustrated, the invention is not to be limited to the specific forms orarrangements of parts so described and illustrated. The scope of theinvention is to be defined by the claims appended hereto and theirequivalents.

1-4. (canceled)
 5. A system that converts polymer containing materialsinto petroleum products, the system comprising: a feedstock receiverinto which feedstock is fed from one end and from which the feedstockexits from the other end; a reactor body to accept the feedstock fromthe receiver and to heat the feedstock to a reaction temperature,wherein the reactor body comprises a horizontal cylindrical body withinternal augers; a controller that adjusts rotation of the reactor body;a second controller that adjusts an incline of the reactor body between0 and 30 degrees; a heating source applied along one or more sides ofthe rotating body to adjust temperatures inside the reactor body; acondensing system to cool vapor products from the reactor body intoliquids and to capture non-vapors; and feedback controls that provideguidance as to conditions required to vary yields of desired productsfrom the system.
 6. A system as in claim 5, wherein the condensingsystem is further configured to condense hot vapor hydrocarbon productsinto non-vapors and liquids within specific boiling temperature rangesand to feed at least a portion of the non-vapors and liquids back intothe reactor body or into a separate reactor for further cracking. 7.(canceled)
 8. A system as in claim 5, wherein the condensing system isfurther configured to collect multiple products at the end of a reactionacross a range of boiling points ranging from light oils to heavy oilsto hydrocarbon gas.
 9. A system as in claim 5, further comprising anadditional multi-stage condensing system having a distillation tower tocontrol the percentage of each end product that is produced.
 10. Asystem as in claim 5, wherein the condensing system is furtherconfigured to capture hydrocarbon gas produced, and the heating sourceis further configured to use at least a portion of the hydrocarbon gasto heat the system.
 11. A system as in claim 5, wherein the condensingsystem comprises several condensers, each with a specific use,including: a first stage condenser that is used as a reflux column; asecond stage condenser that is used to cool vapor into liquids; and athird stage condenser that is used to condense a portion of the vaporinto a liquid stream at a set boiling range.
 12. A system as in claim 5,wherein the feedstock receiver further comprises a single or doublescrew extruder to pre-melt the feedstock and to feed the meltedfeedstock into the reactor body.
 13. A system as in claim 5, furthercomprising at least one additional reactor body to increase throughputcapacity and oil yield, wherein the additional reactor body or bodies iscombined in parallel or in series with the reactor body and are usedconcurrently or sequentially or a combination thereof.
 14. A system asin claim 5, further comprising at least one additional reactor body toprocess unreacted feedstock additional times.
 15. (canceled)
 16. Asystem as in claim 5, further comprising an additional apparatuscontaining a fluid of a known density to separate the feedstock bydensity prior to entering the feedstock receiver.
 17. A system as inclaim 5, further comprising: a shredder or grinder to shred or grind thepolymer containing materials into a smaller size; a feedstock separatorthat separates the shredded or ground materials by weight and size; afeedstock container in which the different polymer containing materialsare separated by density using fluids of known density; a feedstockdrier in which reaction materials are dried. 18-28. (canceled)
 29. Asystem that converts polymer containing materials into petroleumproducts, the system comprising; a shredder or grinder to shred or grindthe polymer containing materials into a smaller size; a feedstockseparator that separates the shredded or ground materials by weight andsize; a feedstock container in which the different polymer containingmaterials are separated by density using fluids of known density; afeedstock dryer in which reaction materials are dried; a feedstockreceiver into which feedstock is fed from one end and from which thefeedstock exits from the other end; a reactor body to accept thefeedstock from the receiver and used to heat the feedstock to a reactiontemperature, wherein the reactor body comprises a horizontal cylindricalbody with internal augers; a controller that adjusts rotation of thereactor body; a heating source applied along one or more sides of thereactor body; and a condensing system to cool vapor products from thereactor body into liquids and to capture non-vapors.
 30. A system as inclaim 29, wherein the condensing system is further configured tocondense hot vapor hydrocarbon products into non-vapors and liquidswithin specific boiling temperature ranges and to feed at least aportion of the non-vapors and liquids back into the reactor body or intoa separate reactor for further cracking.
 31. A system as in claim 29,wherein the condensing system is further configured to collect multipleproducts at the end of a reaction across a range of boiling pointsranging from light oils to heavy oils to hydrocarbon gas.
 32. A systemas in claim 29, further comprising an additional multi-stage condensingsystem having a distillation tower to control the percentage of each endproduct that is produced.
 33. A system as in claim 29, wherein thecondensing system is further configured to capture hydrocarbon gasproduced, and the heating source is further configured to use at least aportion of the hydrocarbon gas to heat the system.
 34. A system as inclaim 29, wherein the condensing system comprises several condensers,each with a specific use, including: a first stage condenser that isused as a reflux column; a second stage condenser that is used to coolvapor into liquids; and a third stage condenser that is used to condensea portion of the vapor into a liquid stream at a set boiling range. 35.A system as in claim 29, wherein the feedstock receiver furthercomprises a single or double screw extruder to pre-melt the feedstockand to feed the melted feedstock into the reactor body.
 36. A system asin claim 29, further comprising at least one additional reactor body toincrease throughput capacity, wherein the additional reactor body orbodies is combined in parallel or in series with the reactor body andare used concurrently or sequentially or a combination thereof.
 37. Asystem as in claim 29, further comprising at least one additionalreactor body to process unreacted feedstock additional times.
 38. Asystem that converts polymer containing materials into petroleumproducts, the system comprising; a shredder or grinder shred or grindthe polymer containing materials into a smaller size; a feedstockseparator that separates the shredded or ground materials by weight andsize; a feedstock container in which the different polymer containingmaterials are separated by density using fluids of known density; afeedstock dryer in which reaction materials are dried; a feedstockreceiver into which feedstock is fed from one end and from which thefeedstock exits from the other end wherein the feedstock receiverfurther comprises a single or double screw extruder to pre-melt thefeedstock and to feed the melted feedstock into the reactor body; areactor body to accept the feedstock from the receiver and used to heatthe feedstock to a reaction temperature, wherein the reactor bodycomprises a horizontal cylindrical body with internal augers; acontroller that adjusts rotation of the reactor body; a secondcontroller that adjusts the incline of the reactor body between 0 and 30degrees; a heating source applied along one or more sides of the reactorbody; a condensing system to cool vapor products from the reactor bodyinto liquids and to capture non-vapors wherein the condensing systemcomprises several condensers, each with a specific use, including afirst stage condenser that is used as a reflux column, a second stagecondenser that is used to cool vapor into liquids and a third stagecondenser that is used to condense a portion of the vapor into a liquidstream at a set boiling range; feedback controls that provide guidanceas to ideal conditions required to vary the yields of the products. 39.A system as in claim 38, wherein the condensing system is furtherconfigured to condense hot vapor hydrocarbon products into non-vaporsand liquids within specific boiling temperature ranges and to feed atleast a portion of the non-vapors and liquids back into the reactor bodyor into a separate reactor for further cracking.
 40. A system as inclaim 38, wherein the condensing system is further configured to collectmultiple products at the end of a reaction across a range of boilingpoints ranging from light oils to heavy oils to hydrocarbon gas.
 41. Asystem as in claim 38, further comprising an additional multi-stagecondensing system having a distillation tower to control the percentageof each end product that is produced.
 42. A system as in claim 38,wherein the condensing system is further configured to capturehydrocarbon gas produced, and the heating source is further configuredto use at least a portion of this hydrocarbon gas to heat the system.43. A system as in claim 38, further comprising at least one additionalreactor body to increase throughput capacity, wherein the additionalreactor body or bodies is combined in parallel or in series with thereactor body and are used concurrently or sequentially or a combinationthereof.
 44. A system as in claim 38, further comprising at least oneadditional reactor body to process unreacted feedstock additional times.